Hollow fiber membrane contactor

ABSTRACT

The present invention is directed to a contactor for degassing a liquid. The contactor includes a perforated core and a microporous membrane fabric wrapped around the core. The fabric includes a polymethyl pentene hollow fiber as a weft fiber and a warp yarn. A tube sheet secures the ends of the wound fiber and a shell encases the tube sheet and fabric. The shell has at least one opening to permit fluid flow through the shell and an end cap. In a further embodiment the invention is directed to a contactor for degassing a liquid wherein the contactor is adapted to withstand pressures greater than 0.4 MPa and temperatures greater than 50° C.

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application is a continuation application from co-pendingU.S. patent application Ser. No. 09/886,653 filed Jun. 21, 2001.

FIELD OF THE INVENTION

[0002] This invention is directed to a hollow fiber membrane contactor.

BACKGROUND OF THE INVENTION

[0003] Hollow fiber membrane contactors are known. For example, see U.S.Pat. Nos. 3,288,877; 3,755,034; 4,220,535; 4,664,681; 4,940,617;5,186,832; 5,264,171; 5,284,584; and 5,449,457, each is incorporatedherein by reference. In general, such contactors utilize a thin walledmembrane to separate, via diffusion, gaseous, solid or liquid componentsfrom a solution or colloidal mixture. Hollow fiber membrane diffusioncontactors are commercially available under the name of LIQUI-CEL® fromCelgard, Inc. of Charlotte, N.C. and under the name of SEPAREL® fromDianippon Ink and Chemicals of Tokyo, Japan (DIC). Such contactors havenumerous uses, one being the degassing of fluids.

[0004] The SEPAREL® contactor comprises a shell surrounding a hollowfiber fabric that is wound around a perforated core. The SEPAREL®contactor uses a fabric made of polymethyl pentene (PMP) hollow fibersand polyester yarn. Hollow fibers made from PMP exhibits uniquediffusion properties. See Japanese Kokai 2-102714 (published Apr. 16,1990). Additionally, the SEPAREL® contactor operating parameters arelimited to a maximum temperature of 50° C. and a maximum feed waterpressure of 0.4 Mpa. See, Hollow Fiber Membrane DegassingModule—SEPAREL®, www.dic.co.jp.

[0005] Commercial PMP fabrics used in the manufacture of contactorsutilize the PMP hollow fibers as the fill or weft and polyester yarns asthe warp yarn. This fabric has a tendency to break if the fabric iswound under tension. One possible explanation for this weakness is theuse of polyester warp yarn in the production of the fabric. Polyester isa relatively stiff material that does not bend and flex well. When a PMPfabric is wound around a mandrel the warp yarns absorb most of theapplied load, thus fabrics using polyester warp yarns break and tear.Fabrics similar to those described in Japanese Kokai 2-102714 have beenshown to break at essentially zero tension during winding. Some degreeof winding tension is desirable to create a well-formed fiber bundlethat fits properly within a contactor shell.

[0006] Another possible explanation for the tearing exhibited by suchPMP fabrics is a failure to utilize properly spaced or sized warp yarn.For example, fabrics similar to those described in Japanese Kokai2-102714 (which tear during winding) exhibit a maximum warp yarn countof approximately 5 lines (yarns) per inch. See JP 2-102714, Embodiment3.

[0007] U.S. Pat. No. 4,911,846 discloses an artificial lung made with ahollow fiber cord fabric. Note, U.S. Pat. No. 4,911,846, FIGS. 11 and12. The cord fabric comprises polyolefin hollow fibers (including PMPhollow fibers), as weft fibers and warp fibers (including polyesters,polyamides, polyimides, polyacrylonitriles, polypropylenes,polyarylates, polyvinyl alcohols, etc.). The warp yarns are preferablymultifilament yarns of polyesters or polyamides having a yarn finenessof 10 to 150 deniers, more preferably 25 to 75 deniers. See U.S. Pat.No. 4,911,846 col. 6, lines 3-14. No information is provided regardingthe spacing of the warp yarn or the makeup of non-polyester,non-polyamide warp yarns.

[0008] Accordingly, a need exists for an improved contactor preferablyemploying a fabric that is not susceptible to breakage and operable athigher temperatures and pressures than known PMP hollow fibercontactors.

SUMMARY OF THE INVENTION

[0009] The present invention is directed to a contactor for degassing aliquid comprising a perforated core and a microporous membrane fabricwrapped around the core. The fabric comprises a polymethyl pentenehollow fiber, as a weft fiber, and a polyolefin warp yarn. In preferredembodiments the fabric has a weft fiber count between 50 and 70 fibersper inch and a warp yarn count between 3 and 12 yarns per inch. A tubesheet secures the ends of the wound fabric and a shell encases the tubesheet and wound fabric. The shell has at least one opening to permitliquid flow through the shell and an end cap.

[0010] In a further embodiment, the invention is directed to a contactorfor degassing a liquid wherein the contactor is adapted to withstandpressures greater than 0.4 MPa and temperatures greater than 50° C. Thecontactor according to this embodiment further comprises a shell and amicroporous membrane fabric comprising a polymethyl pentene hollowfiber, as a weft fiber, and a warp yarn with fiber and yarn countssimilar to those mentioned above. The fabric is preferably wrappedaround a perforated core and situated inside the shell. The shell has atleast one opening to permit the liquid flow through the shell.

DESCRIPTION OF THE DRAWINGS

[0011] For the purpose of illustrating the invention, there is shown inthe drawings a form which is presently preferred; it being understood,however, that this invention is not limited to the precise arrangementsand instrumentalities shown.

[0012]FIG. 1 is a schematic illustration of a hollow fiber membranecontactor.

[0013]FIG. 2 is an illustration of the fabric according to theinvention.

[0014]FIG. 3 is a schematic illustration of a second embodiment of themembrane contactor.

[0015]FIG. 4 is a schematic illustration of a third embodiment of themembrane contactor.

DETAILED DESCRIPTION OF THE INVENTION

[0016] Referring to the drawings wherein like numerals indicate likeelements, there is shown in FIG. 1 an embodiment of a hollow fibermembrane contactor 10 according to the invention. The contactor 10includes a core tube 12. The core tube 12 has a plurality ofperforations 14. Hollow fibers 16 surround the core tube 12. A shell 13surrounds the fibers and the core tube 12. Tube sheets 26 secure thelateral ends of fibers 16 to tube 12. The lateral ends of shell 13 areclosed with end caps 15.

[0017] Referring to FIG. 1, a liquid 18 preferably enters the contactor10 via a liquid inlet 20 of the core tube 12. The liquid 18 travelsthrough the inlet 20 of the core tube 12 and exits the core tube 12 viaperforations 14 when a block 22 diverts the liquid. The liquid 18 thentravels over the exterior surfaces of the hollow fibers 16. The liquid18 re-enters the core tube 12 via perforations 14 on the other side ofthe block 22 and exits the core tube 12 via a liquid outlet 24. Thehollow fibers 16 surround the core tube 12 and are maintained generallyparallel to core tube's 12 axis via tube sheets 26. The hollow fibers 16extend through the tube sheet 26 and are in communication withheadspaces 28 on either end of contactor 10, so that a vacuum 30 drawnat ports 32 and 34 is in communication with the lumen side of hollowfibers 16 via headspaces 28. Port 34, for example, may also be used tointroduce a sweep gas, which facilitates entrained gas removal.

[0018] The membrane contactor 10 is preferably an external flow, hollowfiber membrane module. The membrane contactor 10 has a lumen side and ashell side. The lumen side, also known as the internal side, is defined,in large part, by the lumen of the hollow fiber. The shell side, alsoknown as the external side, is defined, in part, by the external surfaceof the hollow fiber. The liquid travels through the shell (or external)side, while the vacuum (or vacuum and sweep gas) is applied to the lumen(or internal) side. Thereby, entrained gases from the liquid pass, viadiffusion, from the shell side through the membrane to the lumen side.

[0019] Preferably, the hollow fibers 16 are semi-permeable, gasselective, heterogeneous, integrally asymmetric, and liquid impermeablemembranes. The membrane is, preferably, a single layer membrane (e.g.,not a composite or multi-layered membrane) and is made from ahomopolymer of PMP. The membrane is, preferably, a skinned membrane andthe skin is on the shell side. The membrane has a permeability of lessthan 100 Barrers (10⁻⁸ standard cm³.cm/sec.cm².cm(Hg)). For example, seeU.S. Pat. No. 4,664,681, incorporated herein by reference. The totalmembrane in the contactor preferably has an active surface area greaterthan 0.05 m² and most preferably between 0.1 m² to 350 m².

[0020] Referring now to FIG. 2, the hollow fibers 16 are preferably madeinto a fabric 36 having a fill or weft yarn 38 and a warp yarn 40.Preferably the fabric is a weft insertion knitted fabric where the warpyarn is the knitting yarn. The weft yarn 38 is the hollow fiber 16. Thefabric 36 preferably has a weft fiber count between 50 and 70 fibers perinch and most preferably between 60 and 65 fibers per inch.

[0021] The warp yarn 40 should be flexible, yet strong, and inert to theliquid flowing through the contactor. The warp yarns 40 are preferablymultifilament polyolefin yarns. Most preferably the yarns are selectedfrom the group consisting of polypropylene and polyethylene. Thoseskilled in the art recognize that the term filament is sometimes usedsynonymously with cut filament which is also called staple fiber.Accordingly, as used herein the term yarn should be interpreted toinclude yarns made from filament and staple fiber. Preferably, the yarnpossesses a fineness sufficient to resist tearing but not too large asto cause noticeable gaps between fabric layers. Preferably the warp yarnshould be between 80 denier/40 filament (i.e., a 80/40 yarn) and 20denier/10 filament (a 20/10 yarn), most preferably around 40 denier/20filament (a 40/20 yarn). Optionally, the warp yarn may include a surfacefinish, e.g. a silicon oil surface finish.

[0022] The count of the warp yarn is also an important factor in thedesign of the fabric. Too few warp yarns and the fabric will besusceptible to tearing. Too many will diminish the efficiency of thecontactor by blocking surface area of the hollow fibers. In preferredembodiments the warp yarn count is between about 3 and 12 yarns per inchof fabric; most preferably around 6 to 7 yarns per inch.

[0023] When wound, the fabric 36 and the core tube 12 form a hollowmembrane unit 42. Unit 42 is preferably cylindrical. In use, it isexpected that the unit 42 will have a diameter ranging between about 2in. and 16 in. and a length ranging between about 8 in. and 72 in.Larger sizes are possible. The aspect ratio of the unit 42 is defined asL/D² where L is the nominal length of the unit and D is the nominaldiameter of the unit. Preferably, the aspect ratio will range between0.1 to 6.0 in.⁻¹.

[0024] Furthermore, the fabric 36 is preferably wound under tension tocreate a unit 42 having a packing fraction of between about 35% to 45%.Packing fraction (PF) is defined as the number of fibers (n) multipliedby the cross-sectional area of each fiber (A_(f)) divided by thecross-sectional area of the fiber bundle (A_(b)) where thecross-sectional area of the fiber bundle excludes the area occupied bythe core tube 12. Stated symbolically, ${PF} = \frac{n*A_{f}}{A_{b}}$

[0025] Additionally, PMP hollow fibers have a natural tendency to shrinkwhich increases with temperature. Accordingly, in preferred embodimentsof the invention, the PMP fabric 36 is preshrunk prior to winding. Apreferred method of preshrinking and stabilizing the fabric is to heatthe fabric to about 15° C. above the expected operating temperature forapproximately 2 to 8 hours, preferably 4 hours. Heating the fabricbetween about 55° C. and about 65° C. for about 2 to 8 hours, preferably4 hours, should provide adequate fiber stabilization for mostanticipated applications. Preshrinking the fabric and winding the fabricunder tension aids in achieving a well-formed bundle that contributes tothe higher operating parameters (e.g., temperature and pressure)achieved by the invention.

[0026] Hollow fiber membrane units 42 formed according to the inventionmay be combined with other structural elements to create a contactor.Such structural elements are well known in the art and generally consistof an outer shell with at least one opening in the shell to permit fluidflow through the shell. Commonly assigned U.S. patent application Ser.No. 09/816,730, filed Mar. 22, 2001, incorporated herein by reference,discloses several possible structures for contactors, all of which areapplicable to the present invention.

[0027] Referring to FIG. 3, contactor 10′ is the same as shown in FIG. 2but for a flow diverting baffle 50 located within the shell side, andport 34 has been moved. The baffle 50 is added to promote distributionof liquid over all exterior surfaces of the hollow fibers 16. Port 34 ismoved to illustrate the non-criticality of port location.

[0028] Referring to FIG. 4, contactor 10″ differs from contactors 10 and10′ by moving liquid outlet 24 from the terminal end of core tube 12 tothe contactor shell, as illustrated. Vacuum 30 is in communication withheadspace 28 which, in turn, is in communication with the lumens ofhollow fibers 16. The second headspace illustrated in the previousembodiments has been eliminated. Liquid 18 enters the liquid inlet 20 ofthe core tube 12. Liquid 18 exits the tube 12 via perforations 14,travels over the exterior surfaces of the hollow fibers 16, and exitsthe shell side via an outlet 24. The outlet designated 24 may be placedat other locations on the exterior of the contactor so that it maintainscommunication with the shell side.

[0029] The contactor according to the invention may be formed using anyof the methods known by those skilled in the art. One such method is setforth in commonly assigned U.S. patent application Ser. No. 09/851,242,filed May 8, 2001.

[0030] The present invention may be embodied in other specific formswithout departing from the spirit or essential attributes thereof, and,accordingly, reference should be made to the appended claims, ratherthan to the foregoing specification, as indicating the scope of theinvention.

That which is claimed:
 1. A contactor for degassing a liquid comprising:a perforated core; a pre-shrunk microporous membrane fabric wrappedaround said core, said fabric comprising a polymethyl pentene hollowfiber weft and a polyolefin warp yarn wherein the weft count is between50 and 70 fibers per inch, the warp count is between 3 and 12 yarns perinch, and the warp yarn is finer than an 80 denier 40 filament yarn; atube sheet securing the ends of said fiber; a shell encasing said tubesheet and fabric; at least one opening in said shell to permit fluidflow through said shell; and an end cap affixed to the shell.
 2. Acontactor according to claim 1 wherein said polyolefin yarn is a 40denier/20 filament polypropylene yarn.
 3. A contactor according to claim1 wherein said fabric is pre-shrunk by heating said fabric to atemperature between about 55° C. and about 65° C. for about 2 to 8hours.
 4. A contactor according to claim 1 wherein said polymethylpentene hollow fiber is a skinned fiber.
 5. A contactor according toclaim 1 wherein said weft fiber count is between 60 and 65 fibers perinch.
 6. A contactor according to claim 1 wherein the aspect ratio ofsaid fabric is between 0.10 to 6.0 inches⁻¹.
 7. A contactor according toclaim 1 wherein a liquid passes through the shell side of the contactor.8. A contactor according to claim 1 wherein said polymethyl pentenehollow fiber fabric equates to an active membrane area greater than 0.05m².
 9. A contactor according to claim 1 wherein the packing fraction ofthe wound fabric is between about 35% and 45%.
 10. A contactor accordingto claim 1 wherein the said warp fiber count is between 6 and 7 fibersper inch.
 11. A contactor for degassing a liquid: wherein said contactoris adapted to withstand pressures greater than 0.4 MPa and temperaturesgreater than 50° C. and further comprises; a shell; a pre-shrunkmicroporous membrane fabric comprising a polymethyl pentene hollow fiberweft and a warp yarn wherein said weft count is between 50 and 70 fibersper inch and said warp count is between 3 and 12 yarns per inch; and atleast one opening in said shell to permit the fluid flow through saidshell.
 12. A contactor according to claim 11 wherein said warp yarn is apolyolefin yarn finer than an 80 denier 40 filament yarn.
 13. Acontactor according to claim 12 wherein said polyolefin yarn is a 40denier/20 filament polypropylene yarn.
 14. A contactor according toclaim 11 wherein said polymethyl pentene hollow fiber is a skinnedfiber.
 15. A contactor according to claim 11 wherein said fabric has aweft fiber count of between 60 and 65 fibers per inch.
 16. A contactoraccording to claim 11 wherein the aspect ratio of said fabric is between0.10 to 6.0 inches⁻¹.
 17. A contactor according to claim 11 wherein aliquid passes through the shell side of the contactor.
 18. A contactoraccording to claim 11 wherein said polymethyl pentene hollow fiberfabric equates to an active membrane area greater than 0.05 m².
 19. Acontactor according to claim 11 wherein packing fraction of the woundfabric is between about 35% and 45%.
 20. A contactor according to claim11 wherein said warp yarn count is between 6 and 7 yarns per inch.